Rekluse Motor Sports. The z-start Clutch. Husaberg

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1 Rekluse Motor Sports The z-start Clutch Husaberg Installation Guide Copyright Rekluse Motor Sports z-start Revision RMS126 Husaberg Rekluse Motor Sports, inc. 110 E. 43 rd Street Boise, Idaho Created on 6/9/2005 3:54 PM 1

2 Required Tools 8mm socket 10mm socket 27mm socket 4mm allen key socket 3mm allen 1/4 inch driver (for included Torx T10 driver tip) Fine tooth metal file 2 Sets of feeler gauges Inch Pound Torque Wrench Torx T10 driver tip (included) Blue Loctite 243 (oil resistant) z-start Overview Note: The Lower Assembly is packaged underneath the Pressure Plate and held in place with two screws through the Top Plate. Created on 6/9/2005 3:54 PM 2

3 Included Parts for the z-start Clutch Note: spare screws, balls and shims may be included with your clutch Top Plate 2" (51mm)Wave Spring (C200L2) Pressure Plate 2 (51mm) Wave Spring (CS200L1) Lower Assembly 2 x 2 (51mm) Wave Spring Adjustment Washer Clutch Throw-out 12 x M3 #10 torx screws 6 x.047 (1.2mm) Drive plates 6 x M6 Threaded Studs (to assist mounting) 6 x M6 Flat Head Screws 30 x 3/8" (9.53mm) balls 18 x.010 (0.25mm)Mounting Shims 15 x 3/8 (9.53mm) Tungsten Carbide balls 1/4 (6.35mm) ball Throw-out Spacer (1.14mm) Center Clutch Guide ½ (12.7mm) Throw-out Needle Thrust Bearing M Panel Nut ½ (12.7mm) Flat Throw-out Thrust Washer External Tab Lock Washer 1 x (15.9mm) Bellville Spring Washer 12 x M6 1.52mm washers (to go back to stock clutch setup) Basic z-start Clutch Operation The z-start Auto Clutch functions through centrifugal force. As engine RPM increases, the balls contained in the z-start Pressure Plate travel up the ball ramps and push against the Top Plate. This action forces the Pressure Plate to engage the clutch pack. Installation Tips In order for the z-start Clutch to perform properly, it must be mounted properly. Measuring and maintaining the Installed Gap is critical. If the Installed Gap is too big the clutch will slip excessively and cause rapid clutch wear. If the Installed Gap is too small, the clutch will drag and cause engine stall. Recognize that the Pressure Plate travels along the tabs of the Lower Assembly as it engages and disengages. Anything preventing this travel will prevent full engagement and cause the clutch to slip excessively. Be very careful not to drop any screws, washers or springs into the crankcase opening! It is surprisingly easy to drop a little screw or washer down into your crankcase. It is not always so easy to get it out. Make sure all parts going in and coming out are accounted for before you finish the installation. A strong magnetic probe can often be used to retrieve little parts if you happen to drop something in. Bike Preparation and Disassembly 1. Turn the gas petcock to the off position and route the gas cap vent tube into the air. When you lay the bike over on it s side, the gas in the bowl will drain out of the overflow tube. Be prepared to catch the gas in a suitable container to prevent a fire hazard. 2. Carefully lay the bike on its right side so the clutch-cover faces up. 3. Remove the kickstart and shift lever. Remove the clutch cover bolts with an 8mm socket and carefully remove the clutch cover. 4. Using a 5mm allen wrench or 10mm socket, remove the 6 bolts holding the stock pressure plate to the inner clutch hub. Lift off the pressure plate and the clutch lifter assembly. The clutch lifter assembly consists of the Clutch Throw-out, a bearing, and a washer. Pressure plate, 6 bolts and springs, and stock clutch lifter assembly are not reinstalled. 5. Remove your clutch pack and set it aside. Try to keep it in order because it will be re-installed. Created on 6/9/2005 3:54 PM 3

4 Modifying the Stock Center Clutch 6. Remove the center clutch using a 27 mm socket. Take the center clutch to a place where no filings can be dropped into the crankcase opening. Place the included Center Clutch Guide over the studs on the center clutch and use a fine tooth file to file the studs down smooth with the Center Clutch Guide. Remove the guide and use some emery cloth to smooth the studs edges. Note: 12 x M6 x 0.06 washers are provided so the clutch can be re-assembled to the stock configuration. File studs down so they are flush with the included Center clutch guide. 7. Reinstall the center clutch using the thinner Rekluse Multiple External Tab Washer and the Rekluse 18mm Panel Nut with the machined side of the nut facing up. To help keep the tab washer centered it is easiest to center it on the transmission shaft and then fold one of the tabs down against the flat edge of the inner hub of the center clutch. Make sure the machined side of the nut is facing up, apply blue loctite 243, and torque to 50 foot pounds. Installing the Lower Assembly 8. Insert the included M6 Threaded Studs into the bike s center clutch stand-offs 2-3 turns. Carefully place 2 Mounting Shims over each of the studs. See picture below Install M6 studs and carefully place exactly 2 Mounting Shims over each stud. 9. Place the z-start Lower Assembly over the M6 studs. (There are two sets of 6 holes in the Lower Assembly. Use the inner set of holes to mount on the KTM). 10. Carefully remove M6 studs one at a time and replace them with an M6 flat head screw apply blue Loctite 243 to each screw when installing. Make sure none of the Mounting Shims fall out from under the z-start Lower Assembly. Torque the M6 screws to 96 inch pounds. After the screws are torqued-down, the Rotating Hub should spin freely. Created on 6/9/2005 3:54 PM 4

5 11. Follow the following chart when re-installing the clutch pack. Drive Plate Configuration It is necessary to exchange some of the stock steel drive plates in your clutch pack with the Rekluse.047 (1.2mm) drive plates. The stock clutch pack uses.039 (1mm) drive plates and.078 (2mm) Friction Plates. The revised clutch pack setup will remove the top most.039 (1mm) drive plate and exchange two of the stock.039 (1mm) drive plates with Rekluse.047 (1.2mm) drive plates. When finished, the top of the clutch pack should be a friction disk. Refer to the following charts: Stock Clutch Pack Configuration from bottom: (note: this plate is removed permanently) New Clutch Pack Configuration from top to bottom: Top (outer most).047" Rekluse Drive Plate.047" Rekluse Drive Plate Bottom (inner most) Created on 6/9/2005 3:54 PM 5

6 Assembling the Rekluse Throwout, Pressure Plate, and Top Plate 12. Guide the 0.25 Rekluse throw-out spacer ball followed by the Rekluse Clutch throw-out into the hole in the transmission input shaft. Be sure that the spacer is in place between the Stock Clutch throw-out and the throw-out shaft. Place the ½ Needle Thrust Bearing on top of the Rekluse Throw-out followed by the ½ Throw-out Thrust Washer. Place the Belleville Spring washer, curve side down, on top of the flat Thrust Washer. Place the 2 C200L2 Wave Spring on top of the Lower Assembly. The C200L2 Wave Spring is the taller of the two wave springs provided with the kit. This is our recommended setting for engagement RPM refer to the chart on the last page of these instructions for other adjustment settings. See following pictures. Throw-out Spacer Throw-Out Needle Thrust Bearing Flat Throw-out Thrust Washer Wave Spring Belleville Spring Washer Warning: Perform the next step away from the bike to keep the balls from falling into the transmission Place a small amount of oil in each of the Pressure Plates ball grooves. Place 1 Tungsten Carbide ball followed by 1 steel ball. Repeat the pattern until all slots contain a ball. It is very important to have the Tungsten Carbide balls spaced evenly around the Pressure Plate. Note: Tungsten carbide balls are twice as heavy as the steel balls and have a slightly duller gray color. Note: The remaining steel balls are used for adjustment. Created on 6/9/2005 3:54 PM 6

7 14. Place the z-start Pressure Plate over the z-start Lower Assembly. Index the outer tabs of the Pressure Plate into the half-moon windows of the clutch basket. The outer tabs of the Pressure Plate do not rest in the same clutch basket windows as the outer tabs of the friction disks. Also insure that the tabs of the Lower Assembly pass through the associated cut-outs in the Pressure Plate. Make sure the top of the Rekluse Throw-out assembly passes through the hole in the center of the z-start Pressure Plate. See following picture. Throw-out assembly passing through center of Pressure Plate. Tabs Passing through Pressure Plate. 15. While holding the Pressure Plate down place the Top Plate over the Pressure Plate and fasten it to the tabs of the Lower Assembly with three of the M3 screws, through the three marked holes in the Top Plate. Lightly tighten each screw using a 1/4 inch driver and the included Torx T10 driver tip. See following picture. Holding down Pressure Plate until Top Plate is securely fastened. Note: You will have to overcome the z-start Wave Spring and hold the Pressure Plate down until the 3 screws are securely fastened in order to tighten the Top Plate down properly. Created on 6/9/2005 3:54 PM 7

8 Determine the installed gap of the Z-Start 16. Measure the installed gap of the z-start. To do this you will need two sets of feeler gauges. Insert the feeler gauges directly across from one another (180 degrees apart to avoid the clutch pack from rocking resulting in an inaccurate measurement) in the space between the top friction disk and the steel drive plate below it. Find the thickest feeler gauge that still slides back and forth between the two disks with slight resistance. See following pictures. Your installed gap measurement above needs to be between.030 (0.76mm) to.042 (1.07mm) is ideal. If the gap is greater than.042, you need to exchange the next stock.039 (1mm) steel drive plate in the clutch stack and replace it with a Rekluse.047 (1.2mm) steel drive plate. Exchange stock.039 (1mm) drive plates with Rekluse.047 (1.2mm) drive plates or vise versa as needed to get the correct measurement. Repeat steps 16 and 17 until measurement is within range. Final Installation Steps 14. Using a small amount of Blue Loctite 243, install the rest of the M3 torx head screws and torque to 10 inch/pounds. 10 inch-pounds requires a good crank with the included Torx T10 driver tip, but be careful not to bend the head of the T10 driver tip. Remove the three marked M3 screws, add Loctite, and tighten. Note: Use Loctite 243 (Blue, oil resistant) to secure all M3 Torx screws 17. Re-install your clutch cover. Hand-tighten each of the clutch cover bolts, then torque to 6 to 8 foot/pounds in 2 steps. Replace the kick-start and shift lever. WARNING: After a 20 minute break-in period, the clutch plates will seat in and you must re-measure the Installed Gap to guarantee the Installed Gap is within the prescribed range make drive plate adjustments if necessary. See step 16. Clutch break-in re-measurement of the Installed Gap is necessary whenever new clutch plates are installed. WARNING: Refer to the Safety Warnings and Break-in Tuning and Maintenance Guide before operating the z-start clutch. Refer to the next page for adjustment recommendations for the z-start. Created on 6/9/2005 3:54 PM 8

9 Adjusting the z-start Engagement RPM The engine speed at which the z-start begins to engage the clutch, also called the stall speed, can be adjusted. Included with the z-start are two 2 Wave Springs and two 2 Spring Adjustment Washers to fine tune the z-start stall speed. The Wave Springs and Flat Steel Washers are located inside the z-start between the Pressure Plate and Lower Assembly. To adjust the stall speed, it is necessary to remove the engine side cover and the M3 screws holding the z-start Top Plate to access the Wave Spring and Flat Steel Washers. Refer to the z-start Parts View and the installation instructions for detailed information on how to change the Wave Spring and Flat Steel Washer configuration. Use the following chart as a guideline for setting the stall speed. Remember many factors can affect the stall speed from bike to bike so the following chart is only a guideline. You can also make fine tuning adjustments by adjusting your idle speed. CS200L1 Wave Spring 0 x Flat Washers Very Low Stall Speed (generally below a low idle) CS200L1 Wave Spring 1 x Flat Washer Low Stall Speed (typically just above idle) CS200L1 Wave Spring 2 x Flat Washers Medium Stall Speed C200L2 Wave Spring 0 x Flat Washers Medium Stall Speed (very near previous setup) C200L2 Wave Spring 1 x Flat Washers High Stall Speed CS200L1+C150L2 0 x Flat Washers Higher Stall Speed CS200L2+C150L2 0 x Flat Washers Highest Stall Speed Created on 6/9/2005 3:54 PM 9

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